ELECTRONIC POWER SYSTEMS PTY. LTD.

2425

2425

24 Volt 25 Amp Switch Mode Battery Charger

GENERAL FEATURES

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  • Fitted with boost phase time-out timer to avoid excessive
    battery gassing

  • Overheating and short circuit protection

  • IUOU charging characteristic with time limited UO Phase 

  • Fan ventilation 

  • Fully overload protected (auto recovery)! Simple LED charging indicator 

  • For Motor Homes, on Sailing Yachts, Ambulance, and Emergency Vehicles

INPUT

Input:                            207-253 VAC
Frequency:                 50-60 Hz
Protection:                 Internal Primary; Inrush Limiting

Isolation                       Input-Output 3000VAC
                                           Input-Case 2500 VAC
                                           Output-Case 500 VAC

Safety:                            Designed to IEC 950

EMI-EMC:                    FCC Class B, CE, C-TICK
Standard:                      AS 3193
 Input Connection:   3 Core SAA Cable IEC

MECHANICAL

Case Dimension:  325L X 230 W X 102 H 
Casing Material:   Extruded Anodized Aluminum
Weight:                     5.05Kg.
 Cooling:                    
Fan cooled
Warranty:                 12 Months
 

ELECTRICAL

Battery Connection:                    Two
Max. Battery Capacity:              300 A.H
Topology:                                            Switching DC Power
Boost Charge Voltage:                28.8 / 29.6V
Float Charge Voltage:                  27.6VDC
Output Charge Current:            25 Amps
Efficiency:                                            90%
Short Circuit Protection:            Output Shutdown
Over Current Protection:           Secondary Current Limited
R
everse Polarity Protection:     Internal Fuse
Fuse:                                                         T4 A/250V
U0 Phase Limitation:                       4 h or 8 h

ENVIRONMENTAL

Operating Temp. Range:   -5  degrees Celsius to 50 degrees Celsius
Storage Temperature:        30 Celsius to +85 Celsius
Relative Humidity:               10% to 95% non-condensing
Altitude:                                      0-3000m

CHARGING CHARACTERISTIC

The charging characteristic is generally designated as a modified IU0U characteristic

I Phase

At the beginning of the charging process, the empty battery is charged with constant current until the battery voltage reaches 13.8 V or 27.6 V. When the battery reaches this voltage level, the charging current slowly drops. With the drop of the current to the 80 % mark, the charger switches over to the higher charging voltage 14.3 V/14.7 V or 28.6 V/29.4 V

U0 Phase

Here the time registration starts which limits the main charging phase (U0 phase) to a maximum of 4/8 hours. With the switching over of the charging voltage, the current rises again to its maximum value. Now it remains constant as long as the battery voltage is below 14.3 V/14.7 V or 28.6 V or 29.4 V. After reaching the maximum voltage, the current drops again. Thereby the voltage remains constant (U0). Within this main charging phase, which is limited to 4/8 hours, the battery is fully charged.

U Phase

If the current decreases to 10% of the rated current or if the time limit of 4/8 hours is exceeded, then the charger switches over to economy charging (13.8 V or 27.6 V) (U phase).

OPERATION MANUAL

IUOU AUTOMATIC CHARGER

Read these instructions carefully before the installation and commissioning and keep them in a safe place. Pass it on to the buyer in case of the further sale of the system.

Contents

1. Information for Using the Installation Instructions

Warning!
Safety note: Failure in observing these warnings may result in injuries to persons or damage of equipment.

Caution!
Safety note: Failure to observe this warning may result in damage to materials and impair the functioning of the unit.

Caution!
Safety note which points out the dangers involved with electrical current or electrical voltage: Failure to observe this warning may result in damage to materials and impair the functioning of the unit.

Note:
Supplementary information on the operation of the unit.

Action: This symbol indicates to you that you must do something. The actions necessary are described step by step.

This symbol describes the result of an action.

Please also observe the following safety notes.

2. General Safety Information

2.1 General safety

  • Use the IUOU automatic charger only for its use as intended.
  • Use the IUOU automatic charger only in well ventilated rooms.
  • Always interrupt the power supply when doing repair work on the unit!
Warning!
Batteries contain aggressive acids.
  • Avoid the contact with the battery fluid agent.
    If a contact with battery fluid agent should occur, then rinse the affected parts of the body or clothing etc. with plenty cold water.
    It is imperative to seek medical treatment from a doctor with injuries
    caused by acid.
  • Never try to charge a frozen battery.
    There is the danger of explosion!
    In this case, place the battery at a frost-resistant location and wait until the battery has adapted to the ambient temperature. Only then is the charging process started.
  • Store the IUOU automatic charger in a dry and cool place.
  • Maintenance and repair must only be carried out by a qualified specialist who is familiar with the dangers involved and aware of the relevant regulations.

2.2 Safety when handling electrical wires

  • If cables have to be led through sharp-edged walls, use a cable duct or cable bushes!
  • Do not lay any loose or sharp bent cables against electric-conducting materials (metal)!
  • Do not pull at the cables!
  • Fasten the wirings well and lay them in such a way that there is no risk of stumbling occurring and damage to the cable can be excluded.
  • Always use sockets which are earthed and secured by earth leakage circuit breaker.
  • The electrical connection may only be carried out by a specialist firm.
  • Keep to the indicated minimum cable cross-section.
  • Do not lay the 115/230 V line and the 12 V direct current in the same cable conduit (cable duct)!

2.3 Safety when operating the unit 

Caution!
Wrong  installation of electrical units on boats will lead to corrosion of the boat. Therefore, please let a (boat-) electrician carry out the installation of the IUOU automatic charger.

  • Do not operate the IUOU automatic charger if the housing or cables are damaged!
  • Never operate the IUOU automatic charger in a damp or wet environment.
  • Take care that there is a firm position!
    The IUOU automatic charger as well as the battery to be charged must be securely positioned, so that they cannot fall over or down.
  • Ensure that the IUOU automatic charger is kept out of the reach of
    children.
    Dangers may arise which children are not able to recognize!
  • Operate the unit only over a socket which is earthed and secured with an earth leakage breaker.

3. Use As Intended

Batteries which are used on board vehicles or boats for the power generation are charged by the IUOU automatic charger or will be supplied with a conservation voltage.
The IUOU automatic charger are used for the continuous charging of supply batteries or starter batteries. Thus the batteries can be charged or be kept at
a high capacity level.
For the connection possibilities of the various unit variants see Content 4. Description, section 4.2 “Specifications of the Unit Variants”.

The IUOU automatic charger are used for charging the following types of batteries:

  • Lead-acid starter batteries
  • Gel batteries
  • Fleece batteries (A-G-M)
  • maintenance-free batteries

with the capacities and voltages which are indicated in Content 10. “Technical data.” 

Please ask your battery dealer about the max capacities of lead-acid batteries.

Attention
The IUOU automatic charger may not be used in any case for charging other types of batteries (e. g. NiCd, NiMH etc.)!

4. Description

4.1 Operation

Note:
A remote control can be obtained as accessory from us for the IUOU automatic charger. The remote control allows you the possibility of monitoring the unit and switching it ON and OFF.

The unit can be switched over between normal operation and soft operation with the mute function (see Content 5. Installation, section 5.1  “Mute function” ).

The unit is equipped with a wrong polarity protection. A fuse protects against damage of the unit in the case of wrong polarity. Regarding type and valency of the fuse in your unit (see Content 10 “Technical data.”).

Attention
The replace of the unit fuse must only be carried out by a qualified specialist who is familiar with the dangers involved and aware of the relevant regulations.

Note:
A temperature sensor (accessory) which is connected at the battery being charged protects the battery against damage in the case of high or low outside temperature by adapting the charging voltage of the temperature to the battery (see Content 6. Use of the IUOU Automatic Charger, section 6.2  “Charging characteristic.

4.2 Specifications of the unit variants

The IUOU automatic charger are delivered indifferent unit variants.

Your IUOU automatic charger can charge batteries up to a determined battery capacity (see Content 10Technical Data“)

Regarding the identification of the specification of your unit, compare the item number on the type plate with the data in the following tables.

Your IUOU automatic charger has following switches, displays and connections below;

REAR VIEW

Number of Description
  1. Connection for temperature sensor
  2. Unit fuse
  3. Power switch
  4. Connection for 115/230 volts voltage supply
  5. Ventilator

 

FRONT VIEW FOR 2425

The units can charge up to two supply batteries and one starter battery.

Number of Description
  1. Switch for mute function
  2. Connection for remote control
  3. Control lamp
  4. Switch field for the selection of the charging voltage and timer
    function
  5. “+“ (plus) terminal for supply battery
  6. “+“ (plus) terminal for supply battery
  7. “-“ (minus) terminal for supply battery

FRONT VIEW 2425

The units can charge up to two supply batteries and one starter battery.

Number of Description
  1. Switch for mute function
  2. Connection for remote control (accessory)
  3. Control lamp
  4. Switch field for the selection of the charging voltage and timer
    function (see also figure 12)
  5. +“ (plus) terminal for starter battery
  6. “+“ (plus) terminal for supply battery
  7. “-“ (minus) terminal for supply battery.

5. Installation

Attention
Set the power switch at the unit to “0” and pull out the mains plug before connecting or disconnecting the direct current connection.

Note
If you do not have sufficient technical knowledge in respect of the installation and connection of electrical components in the vehicles, let the IU0U automatic charger be installed by a specialist.

Please note the following when installing the unit:

  • Select a well ventilated location which is protected against humidity.
  • The installation surface must be level and of sufficient strength.
  • Make sure that no ventilation surfaces on the unit are covered when
    installing.

For further safety notes when installing the unit (see Content 2. General Safety Information, section 2.2Safety when handling electrical wires“).

5.1  Settings on the Unit

Charging voltage and time limitation
The required charging voltage and the period for the main charging phase (U0 phase, see also Content 6. Use of the IUOU Automatic Charger, section 6.2Charging characteristic“) are selected via a switch field on the unit.

 

Note
Ask your battery dealer for the charging voltage and the required timer setting for your batteries.

Caution!
Make sure that the unit is never operated when the switches 1 and 2 or 3 and 4 are at the same time in position “ON“. Only the switch positions as described in the following tables ensure correct functioning of the IUOU automatic charger.

Settings for the charging voltage for 2415 & 2425

Settings for the limitation of the period of the main charging phase:

Mute Function
If the mute function is switched on, then the unit is operated without active
cooler. Thereby the noise development decreases and the charging capacity
is reduced.

Switch the mute function of the unit ON and OFF with the switch at the front (see figure below, number 1)

5.2  Connecting the IUOU automatic charger Battery

Warning!
Absolutely avoid contact with the battery fluid!

Caution!
Batteries with cell connection may not be charged, since explosive gases could occur by overheating the battery.

Note:
Only use cables with the prescribed wire-cross sections for the connection of the IUOU automatic charger to the battery:

  • Lay the cables from the batteries to the IUOU automatic charger.
  • Crimp the cable ends with the multicore cable ends.

Note:
Use for the connection of starter batteries to the unit variants 1225-TC and 2415-TC the specially intended terminal (see figure below).

Provide the cable with a fork connection for an optimum connection with the terminal (see figure below).

Note
The negative pole of the battery is earth-connected in the connected status.

Attention
Ensure correct polarity. The internal flat-pin terminal triggers with the wrong polarity of battery and battery charger. The repair must only be carried out by skilled personnel familiar with the dangers involved and aware of the relevant regulations.

Connect the “-“ (minus) battery pole with a connecting cable with the ”-“ (minus) terminal at the IU0U automatic charger (see figure below).


Connect the “+“ (plus) battery pole with the connecting cable with the “+“ (plus) terminal at the IUOU automatic charger (see below).

Temperature sensor (can be obtained from us as accessory)

The temperature sensor measures the temperature at the battery or in the
environment of the battery and transfers it to the IUOU automatic charger. The charging voltages indicated in Chapter „Technical data“ on page 26 refer to an ambient temperature of 15 °C to 25 °C. With deviating temperatures, the charging voltage is increased or decreased according to the diagram below.

  • Lay the cables from the batteries to the IUOU automatic charger.
  • Connect the temperature sensor to the rear of the IUOU automatic charger (see figure below) via the socket.
  • Fasten the sensor head directly to the battery. Use e.g. double-sided adhesive tape for this and attach the sensor to the upper side of the battery or in the vicinity of the battery.
  • Switch the IUOU automatic charger “OFF“ and “ON“ again to activate
    temperature sensor.

Remote control (can be obtained from us as accessory)

The remote control serves for switching ON and OFF and for the functional check (see Chapter “Functional check“) of the IUOU automatic charger.

Note:
Attach the remote control at a well accessible place to ensure an optimal remote control and check of the IUOU automatic charger.

Caution!
Pay attention when attaching the remote control (when drilling and screwing) to the course of the available, particularly non-visible wiring harnesses, cables and other components which are in the assembly range!

  • Lay the cables from the batteries to the IU0U automatic charger.
  • Make an oblong convexity in the assembly surface with approximately 50 mm width, 55 m height and 23 mm depth for the take-up of the remote control.
  • Connect the remote control on the rear with the intended connection (see Chapter “Specifications of the unit variants” ) via the bush at the IUOU automatic charger. The connection cable is equipped with two equivalently allocated modular plugs.
  • Insert the remote control into the opening created so that the faceplate of the remote control rests completely on it.
  • Screw the remote control with two screws to the upper and bottom margin of the faceplate – use the available drills.

230 Volts Voltage Supply

Connect the plug of the 115/230 volts voltage supply at the unit to an earthed
socket which is secured by an earth leakage circuit breaker.

6.  Use of the IU0U Automatic Charger

For the safety notes when operating the unit see also Content 2. General Safety, section 2.3Safety when operating the unit.”

With the IUOU automatic charger you can either recharge batteries or supply empty batteries with a conservation charge.

Switch the unit on with the power switch on the rear side of the unit.

 

6.1 Switching on and off with the remote control 
(can be obtained from us as accessory)

Note:
The power switch at the unit (see Fig. 7-9, page 6) must be switched on, so that the unit can be switched ON and OFF with the  remote control. 

Press the key “ON/OFF” on the remote control to switch ON or OFF.

6.2 Charging characteristic 

The charging characteristic is generally designated as a modified IUOU characteristic.

I phase

At the beginning of the charging process, the empty battery is charged with constant current until the battery voltage reaches 13.8 V or 27.6 V. When the battery reaches this voltage level, the charging current slowly drops. With the drop of the current to the 80 % mark, the charger switches over to the higher charging voltage 14.3 V/14.7 V or 28.6 V/29.4 V.

Note
The charging voltage and the period for the main charging phase (UO phase) can be selected via a switch field (see Content 5. Installation, section 5.1Settings on the Unit“)

UO Phase

Here the time registration starts which limits the main charging phase (UO phase) to a maximum of 4/8 hours. With the switching over of the charging voltage, the current rises again to its maximum value. Now it remains constant as long as the battery voltage is below 14.3 V/14.7 V or 28.6 V or 29.4 V. 

After reaching the maximum voltage, the current drops again. Thereby the voltage remains constant (UO). Within this main charging phase, which is limited to 4/8 hours, the battery is fully charged. 

U phase

If the current decreases to 10% of the rated current or if the time limit of 4/8 hours is exceeded, then the charger switches over to economy charging (13.8 V) (U phase). 

Note
In the case of chargers with double charging or three-fold charging connection there exists the possibility of charging batteries separately from each other. The outputs are separated internally via diodes. The weaker battery is always first set to charging level of the stronger battery. The charging characteristics the same as described above. 

Attention
The maximum battery capacity (see Content 10 “Technical Data”) on could not be exceeded in order not to influence the functions of the individual charging phases. 

Only for units with temperature sensors that are optionally available.
Adapting the charging voltage dependent on the battery temperature. A temperature sensor can be connected for to provide the optimum charging functioning. The charging voltages, as can be seen from the diagram, are raised or dropped dependent on the battery temperature. 

Note
The battery chargers WT-1215-TB, WT-1215-TC and WT-2415-TC have a charging output for the starter battery. The output voltage is between 13.2 V (26.4 V) and 13.8 V (27.6 V) and can recharge the starter battery with a current of 1 A or keep it at a high capacity level. 

6.3 Functional check

The charging process of the batteries can be checked via an LED at the front of the unit:

Note
The check of the unit can occur also with the optionally available remote control. The LEDs on the remote control indicate the colours and the appropriate charging phases.

7. Servicing and Cleaning 

Caution!
Never use sharp or hard detergents as they can damage the unit. 

Clean the outside of the IU0U automatic charger from time to time with a damp cloth.

 

8. Troubleshooting

Please contact the Battery Manufacturer with detailed questions regarding the battery data.

After the connection and commissioning of the IU0U automatic charger, the voltage in the battery does not increase.

  • Measure, if possible, with a suitable multimeter during the charging whether the voltage at the battery terminals increases or not.
  • Check whether the terminals are connected properly with the battery poles.
  • Clean the battery poles if necessary.

 

The battery is not fully charged after a charging time of approximately 20 hours.

  • Disconnect the IU0U automatic charger from the mains. 
  • Remove the charging terminals from the battery and wait for some minutes.
  • Now measure the voltage at the battery terminals with a suitable multimeter.

 

12V Battery

If the multi meter displays a voltage of 10 V or less, it means that the battery is defective and does not charge any longer.

  • Let the battery be checked by a specialist, if necessary, or dispose of the battery.

 

24 V battery

The multimeter indicates a voltage of 20 V or below.

  • Let the battery be checked by a specialist, if necessary, or dispose of the battery.

The battery discharges already after short time without load.

  • Now measure the voltage at the battery terminals with a suitable multimeter.

If the multimeter indicates a voltage below 12 V at a 12 V battery or a voltage below 24V at a 24 battery, then the battery is too weak to keep the charge.

  • Let the battery be checked by a specialist, if necessary, or dispose of the battery. 

9.  Disposal

9.1 Dispose of the Packing Material

Do not throw the packing material away. The following indications must be therefore considered:

  • Take the packing material made of cardboard to a waste paper collection for recycling.
  • Put the plastic packing into the yellow dustbin.
  • Enquire, if necessary, at your local government office about the location of the Recycling Centre which is responsible for you.

 

9.2 Dispose of the used unit

If you put the IU0U automatic charger finally out of operation, please bring it o the next Recycling Centre, or to your specialist dealer, who will take it back against a small fee to cover costs. 

 

9.3 Dispose of the Batteries

Protect your environment!

Do not throw defective batteries into the domestic waste.

Please return the used or defective battery to the dealer or dispose of it at an authorized waste collection point.

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